Manufacturing method for molded vehicle ceiling

Abstract

To provide a manufacturing method for a molded vehicle ceiling that stabilizes a quality of end processing in the molded vehicle ceiling, reduces a thermal management burden on workers in an end processing, and allows workers to work more safely.SOLUTION: A manufacturing method for a molded ceiling by terminating a periphery of an opening 12 of the molded ceiling 10 includes: a placing step of placing the molded ceiling 10 on a base 20; a folding step of folding an edge part 15 so as to fit a back surface 10b of the molded ceiling 10 by a bending piece 23 functioning as a first ultrasonic horn; a pressing step of pressing the edge part 15 toward a receiving part 21a of the base 20 by a first tip part 24 so that the bent edge part 15 and the back surface 10b of the molded ceiling 10 are in close contact with each other; and a first welding step in which the edge part 15 pressed by the first tip part 24 and the back surface 10b of the molded ceiling 10 are ultrasonically welded via the first tip part 24 to form a welded rolled part 14.SELECTED DRAWING: Figure 7

Description

[Technical field]

[0001] The present invention relates to a method for manufacturing a molded vehicle headliner. [Background technology]

[0002] Conventionally, the end of a molded ceiling, which is an automobile interior part, has been treated by various methods to improve the appearance of the end of the product. For example, there is a method in which the backing material at the end of the molded ceiling is peeled off to leave only the skin, and after applying an adhesive, the skin is rolled up by hand. There is also a method in which the backing material is heated and melted by applying hot air or by contacting a high-temperature piece, and then the end part is rolled up using a roll-up piece. Patent Document 1 discloses a method for treating the end of the skin at the opening for the sunroof of a molded ceiling, in which the roll-up margin of the skin is heated and softened with a hot air nozzle, and then the skin is rolled up along the edge of the opening by moving the roll-up piece. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2008-143455 A Summary of the Invention [Problem to be solved by the invention]

[0004] However, when wrapping the skin manually, it is necessary to become proficient in the work, and the stability of the quality tends to depend on the worker. On the other hand, when the backing material is heated and melted after the molded ceiling is set in the jig, and the end is processed with a rolling block, the skin can be wrapped automatically, but since the block needs to be heated, it has to be kept running even when the wrapping work is not being done, which tends to increase utility costs. In addition, when the worker sets or removes the product, a high-temperature hot air outlet or heating block is always waiting, and it is necessary to pay close attention not to come into contact with the hot parts.

[0005] The present invention was devised in consideration of these points, and the problem that the present invention aims to solve is to provide a manufacturing method for molded vehicle ceilings that stabilizes the quality of end processing in molded vehicle ceilings, reduces the burden of heat management on workers in end processing, and allows workers to work more safely. [Means for solving the problem]

[0006] One feature of a manufacturing method for a molded ceiling for a vehicle that solves the above problem is a manufacturing method for a molded ceiling for a vehicle, which comprises molding a molded ceiling by applying pressure with a mold having a molding surface formed into a required curved surface, and then bending an edge portion along the periphery of an opening provided in the molded ceiling toward the back side of the molded ceiling and adhering it to the back side of the molded ceiling, the molded ceiling being configured to have a planar backing material containing a thermoplastic resin on its back side, and the molded ceiling being mounted on a support surface of a base having a receiving portion that supports the periphery of the opening, the front side of the molded ceiling facing the support surface of the base, and the edge portion being bent from the receiving portion to the base. The method includes a placing process in which the edge portion is placed so that it extends outside the molded ceiling; a folding process in which a bending piece having a first tip portion capable of transmitting ultrasonic vibrations and functioning as a first ultrasonic horn is used to bend the edge portion so that it fits along the back surface of the molded ceiling; a pressing process in which the first tip portion is used to press the edge portion toward the receiving portion of the base so that the edge portion bent in the folding process is in close contact with the back surface of the molded ceiling; and a first welding process in which the edge portion pressed by the first tip portion and the back surface of the molded ceiling are ultrasonically welded together via the first tip portion to form a welded rolled portion.

[0007] One feature and advantage of the above process is that the peripheral edge of the opening in the molded ceiling is bent toward the back surface of the molded ceiling by a bending piece that functions as a first ultrasonic horn. The bent edge is pressed by a first tip of the bending piece. This allows ultrasonic vibration to be transmitted through the first tip while the edge and the back surface of the molded ceiling are in closer contact with each other, and the edge can be reliably ultrasonically welded to the back surface of the molded ceiling. Therefore, a series of processes for bending the end of the opening in the molded ceiling and welding it to the back surface of the molded ceiling can be performed automatically, and the quality of the end processing can be stabilized. In addition, since the bending piece also serves as a jig for bending and ultrasonic welding, there is no need to provide a heating piece or a hot air duct for heating the edge of the molded ceiling separately from the bending piece, and this can reduce the burden of heat management on the worker and the energy cost for residual heat. Furthermore, when the worker sets or removes the product, the number of high-temperature areas around the worker can be reduced, improving the safety of the work.

[0008] Regarding the manufacturing method for the above-mentioned molded ceiling for a vehicle, the bending process may include a first bending process in which the bending piece is moved in the entry direction of a first moving locus that approaches the edge portion of the molded ceiling placed on the base from the surface side of the molded ceiling, so that the first tip portion comes into contact with the edge portion of the molded ceiling, and further the bending piece is moved to a position where the first tip portion does not leave the edge portion, thereby bending the edge portion from the surface side to the back side of the molded ceiling, and a second bending process in which the bending piece is moved in the entry direction of a second moving locus that approaches the back side of the molded ceiling placed on the base, thereby further folding the edge portion bent in the first bending process so that it follows the back side of the molded ceiling.

[0009] One feature and advantage of the above process is that the folding process includes a first folding process and a second folding process. The edge of the opening in the molded ceiling is folded partway along the folding direction by the folding piece moving in the entry direction of the first movement locus, and the first tip part moving to a position where it abuts against the edge and does not separate from the edge. Then, the folding piece moves from that state in the entry direction of the second movement locus, so that the edge is further folded along the back surface of the molded ceiling. Therefore, it is possible to suppress the occurrence of variation in the base point for folding the edge depending on the product.

[0010] Regarding the manufacturing method for the above-mentioned molded ceiling for a vehicle, the pressing process may include a retracting process of moving the folding piece so as to retract the first tip portion in the thickness direction of the edge portion further folded in the second folding process until the edge portion and the back surface of the molded ceiling come into surface contact, and the edge portion may be pressed by the first tip portion retracted in the retracting process.

[0011] One feature and advantage of the above process is that in the pressing step, the folding piece is moved so as to pull in the first tip in the thickness direction of the edge portion folded in the second folding step. This presses the edge portion close to the back surface of the molded ceiling, folding it more firmly. Therefore, even if there is a gap between the edge portion and the back surface of the molded ceiling, the edge portion and the back surface of the molded ceiling can be tightly attached to each other, and ultrasonic vibrations can be transmitted to the required area.

[0012] Regarding the manufacturing method for the above-mentioned molded ceiling for a vehicle, the first bending process may include a plate-shaped support member that is arranged to be able to move forward and backward so as to approach and move away from the first tip portion, and whose plate surface faces the mounting surface of the base, and includes an action of the support member entering so as to approach the back side of the edge portion of the molded ceiling placed on the base, and an action of the tip of the support member being positioned with respect to the molded ceiling so as to contact the folding base point of the edge portion, and is a process in which the edge portion is folded onto the plate surface of the support member by moving the folding piece in the entry direction of the first movement locus, and after the edge portion is folded in the first bending process, the support member is retracted, and the second bending process is performed after the support member is retracted.

[0013] One feature and advantage of the above process is that in the first bending process, the plate-shaped support member sandwiches the edge of the molded ceiling and enters a position facing the first tip of the bending piece and waits. The tip of the support member contacts the folding base point on the back side of the edge. As a result, the folding piece moves in the entry direction of the first movement trajectory, and the edge of the molded ceiling is folded onto the plate surface of the plate-shaped support member. Therefore, even if the edge is difficult to bend due to the material composition of the molded ceiling or the shape of the opening, the edge can be folded in a stable position using the tip of the support member as the base point.

[0014] Regarding the manufacturing method for the above-mentioned molded ceiling for a vehicle, the molded ceiling may have a recess that is recessed in the thickness direction from the back side of the molded ceiling or a notch that is cut in the thickness direction at the folding base point of the edge portion, and the edge portion may be folded at the folding base point in the first folding process and the second folding process.

[0015] One feature and advantage of the above process is that at the folding base point of the molded ceiling, a recess recessed from the back side in the thickness direction or a cut in the thickness direction is provided. This makes it easier for the base material to bend at the folding base point regardless of the material of the molded ceiling, and the folding base point is positioned, making it possible to fold the edge portion at a stable position in the first folding process. Also, when the edge portion is further folded in the second folding process, a neater folding can be achieved.

[0016] The manufacturing method for the above-mentioned molded ceiling for a vehicle may include a placement process of placing a reinforcing member to reinforce the periphery of the opening in at least a portion of the peripheral area of ​​the opening on the back surface of the molded ceiling, and a fixing process of fixing the reinforcing member to the back surface of the molded ceiling, wherein the fixing process is performed between the second bending process and the end of the first welding process.

[0017] One feature and advantage of the above process is that by arranging and fixing a reinforcing member in the peripheral area of ​​the opening in the molded ceiling, the strength of the peripheral area of ​​the opening can be improved. Also, by performing the fixing process of the reinforcing member between the second bending process related to the edge and the end of the first welding process, the reinforcing member can be fixed at the same time as the terminal processing on the periphery of the opening in the molded ceiling. Therefore, the post-process can be shortened.

[0018] Regarding the above-mentioned manufacturing method for a molded ceiling for a vehicle, the fixing process may be a manufacturing method that includes a second welding process in which the reinforcing member is ultrasonically welded to the back surface of the molded ceiling by a reinforcing piece having a second tip portion capable of transmitting ultrasonic vibrations and functioning as a second ultrasonic horn.

[0019] One feature and advantage of the above process is that in the second welding process, the reinforcing member is ultrasonically welded in at least a part of the peripheral area of ​​the opening in the molded ceiling by the reinforcing piece that functions as a second ultrasonic horn. By performing the second welding process between the second folding process and the end of the first welding process, the reinforcing member can be welded at the same time as the terminal processing on the periphery of the opening in the molded ceiling. Therefore, the post-processing can be shortened.

[0020] Regarding the above-mentioned manufacturing method for a molded ceiling for a vehicle, the reinforcing piece may have a holding portion at the second end portion capable of holding the reinforcing member, and the placement process may be a manufacturing method in which the reinforcing piece is moved in a direction in which the second end portion approaches the back surface of the molded ceiling placed on the base while holding the reinforcing member with the holding portion, thereby placing the reinforcing member in the peripheral area of ​​the opening.

[0021] One feature and advantage of the above process is that in the placement process, the reinforcing member is held by the holding portion of the reinforcing piece and moved toward the back surface of the molded ceiling to be placed in the peripheral area of ​​the opening. Then, ultrasonic vibrations are transmitted via the second tip of the reinforcing piece to ultrasonically weld the placed reinforcing member to the back surface of the molded ceiling. Therefore, the reinforcing member can be placed in the peripheral area of ​​the opening automatically instead of manually, and the process up to ultrasonic welding to the back surface of the molded ceiling can be carried out efficiently.

[0022] The above-mentioned method for manufacturing a molded vehicle ceiling may be a manufacturing method in which the fixing step is carried out simultaneously with the first welding step.

[0023] One feature and advantage of the above process is that by simultaneously fixing the reinforcing member to the back surface of the molded ceiling and welding the edge portions, the post-processing of end treatment can be shortened, thereby improving the efficiency of the entire process.

[0024] The manufacturing method of the above-mentioned molded ceiling for a vehicle may be a manufacturing method in which the reinforcing member is made from scrap material of a portion of the molded ceiling that has been removed to form the opening.

[0025] One feature and advantage of the above process is that the remnants of the parts removed to form the opening are used as reinforcing members for reinforcing the periphery of the opening in the molded ceiling. In other words, the material of the molded ceiling can be effectively utilized, and the yield can be improved.

[0026] The manufacturing method for the above-mentioned vehicle molded ceiling may be a manufacturing method in which the reinforcing member is selected from the group consisting of plastic, resin, metal plate, and wood.

[0027] One feature and advantage of the above process is that the reinforcing members are selected from plastic, resin, metal plate, or wood, i.e., a molded ceiling can be manufactured in which the peripheral area of ​​the opening is reinforced with reinforcing members made of various materials. Effect of the Invention

[0028] By using the above process, the present invention can provide a manufacturing method for molded vehicle ceilings that stabilizes the quality of end processing in molded vehicle ceilings, reduces the burden of heat management on workers in end processing, and allows workers to work more safely. [Brief description of the drawings]

[0029] [Figure 1] FIG. 2 is a diagram showing a schematic plan view of a molded ceiling according to an embodiment. [Diagram 2] 1 is a diagram showing a cross-sectional configuration of a molded ceiling according to an embodiment of the present invention; [Diagram 3] FIG. 4 is a diagram illustrating an arrangement of a jig for terminal processing according to the embodiment. [Figure 4] 5A to 5C are diagrams illustrating a first folding step according to the embodiment. [Diagram 5] FIG. 10 is a diagram illustrating a state in which the support member returns to a predetermined position (standby position) after a first bending step according to the embodiment. [Figure 6] 6A to 6C are diagrams illustrating a second folding step and a reinforcing member arrangement step according to the embodiment. [Figure 7]5A to 5C are diagrams illustrating a pressing step and a second welding step according to the embodiment. [Figure 8] 4A to 4C are diagrams illustrating a first welding step according to the embodiment. [Figure 9] 11 is a diagram showing a state in which a folding piece is returned to a fixed position after a first welding step according to the embodiment; FIG. [Figure 10] FIG. 13 is a diagram showing a modification of the above embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0030] <Configuration of vehicle ceiling mold> Hereinafter, an embodiment of the present invention will be described with reference to the drawings. A roof of a vehicle is configured with a ceiling panel made of steel plate. The ceiling panel may be provided with an opening for a sunroof. A molded ceiling 10 for a vehicle according to the first embodiment is a ceiling material attached to the interior side of the ceiling panel provided with this opening, and an opening 12 is provided in the center of the molded ceiling 10 in a position opposite to the opening of the ceiling panel (see FIG. 1).

[0031] As shown in FIG. 2, the molded ceiling 10 is formed into a three-dimensional surface shape by heating and pressing a base material layer 2, a backing material 3, and a skin material 4. The base material layer 2 is composed of, for example, a core material and a fiber reinforcement material laminated on both sides of the core material. The core material is provided to maintain the shape and ensure the rigidity of the molded ceiling 10, and may also have sound absorption and heat insulation in the vehicle cabin. The core material may be of various types, such as fiber-based, cardboard-based, urethane-based, and olefin-foam-based. For example, urethane foam is selected as the core material according to this embodiment. The fiber reinforcement material is applied or impregnated with a thermosetting adhesive on its surface and is bonded to both sides of the core material, contributing to the shape retention and rigidity improvement of the molded ceiling 10. In addition, a nonwoven fabric layer may be laminated between the fiber reinforcement material and the skin material 4 on the inside of the vehicle cabin of the base material layer 2.

[0032] The backing material 3 is laminated along the surface of the base layer 2 on the vehicle body side (ceiling panel side). The backing material 3 is made of a material containing a thermoplastic resin, and various synthetic fiber nonwoven fabrics such as polyamide-based, polyester-based, polyacrylonitrile-based, etc. may be used. In addition, a non-breathable resin film may be laminated between the backing material 3 and the base layer 2.

[0033] The skin material 4 is laminated along the surface of the base layer 2 facing the interior of the vehicle. The skin material 4 is a part that is responsible for the design surface of the molded ceiling 10. The skin material 4 is selected, for example, from a surface layer and a urethane foam sheet laminated together. The surface layer can be made of various materials such as fabric, cloth, knitted fabric, woven fabric, nonwoven fabric, thin wool fabric, synthetic leather, artificial leather, genuine leather, etc. The urethane foam sheet is laminated by applying a soft layer made of urethane resin foam to the molded ceiling 10 to give it a soft feel. It is also possible to adopt a configuration in which the urethane foam sheet is not laminated.

[0034] As shown in FIG. 1, an opening 12 is provided in the center of the molded ceiling 10. The periphery of the opening 12 is terminated to form a rolled-up portion 14. Specifically, an edge portion 15 along the periphery of the opening 12 is bent toward the back surface 10b (the surface on the ceiling panel side) of the molded ceiling 10 and fixed to the back surface 10b of the molded ceiling 10 by ultrasonic welding (see FIG. 9). That is, the rolled-up portion 14 is formed by melting the thermoplastic resin contained in the backing material 3 by ultrasonic vibration at the bonding surface between the edge portion 15 and the back surface 10b of the molded ceiling 10 and then solidifying it. The edge portion 15 is formed by folding the skin material 4, the base material layer 2, and the backing material 3 in a laminated state together. By including not only the skin material 4 but also the base material layer 2 in the edge portion 15, the strength of the area where the rolled-up portion 14 is formed can be improved.

[0035] The periphery (peripheral region) of the opening 12 of the molded ceiling 10 tends to be a region with a relatively low moment of area. Therefore, the reinforcing member 6 is arranged in the opening peripheral region 16 and fixed to the back surface 10b of the molded ceiling 10. Here, the opening peripheral region 16 includes the region where the rolled-in portion 14 is formed and the region around it. The reinforcing member 6 is formed in a flat plate shape and a band shape, for example, using the scrap material of the portion removed to form the opening 12 in the manufacturing process of the molded ceiling 10. Then, for example, the reinforcing member 6 is arranged in a position or region adjacent to the rolled-in portion 14, and is fixed to the back surface 10b of the molded ceiling 10 by ultrasonic welding. The reinforcing member 6 may be arranged around the entire periphery of the opening peripheral region 16, or may be arranged only in a part of the region. The reinforcing member 6 may be made of various materials, such as scrap materials of the materials constituting the molded ceiling 10, as well as plastic, resin, metal plate, wood, and the like. The method of fastening the reinforcing member 6 to the rear surface 10b of the molded ceiling 10 may be selected according to the material of the reinforcing member 6, such as ultrasonic welding, adhesion with adhesive, double-sided tape, or the like.

[0036] <Tool for terminal processing> Next, a description will be given of a jig used for processing the ends of the opening 12 in the molded ceiling 10. As shown in Fig. 3, the jig for processing the ends according to this embodiment includes a base 20, a bending piece 23, a reinforcing piece 27, and a support member 30.

[0037] The base 20 has a support surface 21 on which the molded ceiling 10 to be terminated is placed, and can support the molded ceiling 10 during the termination process. The base 20 has a receiving portion 21a on the support surface 21 that supports the periphery of the opening 12 in the molded ceiling 10. The receiving portion 21a has an inclined surface formed, for example, to follow the surface shape of the periphery of the opening 12. During the termination process, the receiving portion 21a supports the area surrounding the opening 12 of the molded ceiling 10, the edge portion 15, etc.

[0038] The bending piece 23 bends the edge portion 15 along the periphery of the opening 12 toward the back surface 10b of the molded ceiling 10, and also functions as a first ultrasonic horn to ultrasonically weld the bent edge portion 15. The bending piece 23 is configured to be movable forward and backward in the horizontal and vertical directions, for example by a cylinder, and is disposed at a position adjacent to the receiving portion 21a of the base 20. In this embodiment, the opening peripheral region 16 where the rolled-up portion 14 is formed is divided into multiple sections along the periphery of the opening 12 of the molded ceiling 10, and multiple bending pieces 23 are disposed to correspond to the divided regions (for example, A to L shown in FIG. 1).

[0039] The folding piece 23 is configured to move from a predetermined position (standby position) in an approaching direction 23X1 of a first movement locus and further move in an approaching direction 23Y1 of a second movement locus in a folding process described later (see Figs. 4 and 6). Here, the first movement locus is a locus along which a first tip portion 24 of the folding piece 23 described later moves so as to approach an edge portion 15 of the molded ceiling 10 placed on the base 20 from the front surface 10a (the surface on the vehicle interior side), and is the front-rear direction shown in Figs. 3 to 9. The approaching direction 23X1 of the first movement locus is the front direction. The second movement locus is a locus along which the first tip portion 24 moves so as to approach the back surface 10b of the molded ceiling 10 placed on the base 20, and is the up-down direction shown in Figs. 3 to 9. The approaching direction 23Y1 of the second movement locus is the downward direction.

[0040] The bending piece 23 has a first tip 24 capable of transmitting ultrasonic vibration. The first tip 24 is formed to have a hook shape in a side view and can be engaged with the receiving portion 21a (inner side) of the base 20. In addition, the transmission surface 24a of the first tip 24 for transmitting ultrasonic waves is formed to match the inclined surface of the opposing receiving portion 21a. With these configurations, the bending piece 23 moves in the approach direction 23X1 of the first movement trajectory, so that the first tip 24 comes into contact with the edge portion 15, and the edge portion 15 is bent into a dogleg (see FIGS. 4 and 5). Then, the bending piece 23 moves in the approach direction 23Y1 (downward direction) of the second movement trajectory, so that the edge portion 15 is sandwiched between the first tip 24 and the receiving portion 21a, and is bent toward the back surface 10b of the molded ceiling 10 (see FIG. 6). In other words, the bending piece 23 can bend the edge portion 15 toward the back surface 10b of the molded ceiling 10 by the first tip portion 24 moving around the bending base point of the edge portion 15, and further bend it so that it is close to the back surface 10b.

[0041] In addition, the folding piece 23 can move from the position in the direction opposite to the approach direction 23X1 of the first movement trajectory (retraction direction 23X2) so as to sandwich the edge portion 15 close to the back surface 10b of the molded ceiling 10 between the transmission surface 24a of the first tip portion 24 and the receiving portion 21a of the base 20 after further folding the edge portion 15 toward the back surface 10b (see FIG. 7). By moving the folding piece 23 in the retraction direction 23X2 in this way so as to pull in the first tip portion 24, the edge portion 15 can be further folded firmly and pressed toward the receiving portion 21a of the base 20. In other words, the transmission surface 24a of the first tip portion 24 also acts as a pressing surface that presses the edge portion 15.

[0042] The ultrasonic transmitters connected to the bending pieces 23 may be configured, for example, by disposing the same number of transmitters as the bending pieces 23, with each transmitter emitting ultrasonic waves to each of the bending pieces 23. This allows the roll-up portion 14 to be formed simultaneously in a plurality of divided areas. Alternatively, for example, a number of transmitters less than the number of bending pieces 23 may be disposed, with one transmitter emitting ultrasonic waves to a plurality of bending pieces 23. In this case, ultrasonic welding is performed sequentially for each divided area (part), so a slight takt time is required in the first welding process described below, but by reducing the number of transmitters, the cost of the equipment can be reduced.

[0043] The reinforcing piece 27 arranges the reinforcing member 6 in the opening peripheral region 16 and functions as a second ultrasonic horn to ultrasonically weld the arranged reinforcing member 6. The reinforcing piece 27 is configured to be movable up and down by, for example, a cylinder, and is appropriately arranged above the base 20 according to the position and number of the reinforcing members 6. The reinforcing piece 27 is configured to descend so that the second tip 28 approaches the back surface 10b of the molded ceiling 10 placed on the base 20, and the descending position is set so that the reinforcing piece 27 does not come into contact with the first tip 24 of the folding piece 23 when descending. The reinforcing piece 27 has a second tip 28 capable of transmitting ultrasonic vibration. The transmission surface 28a of the second tip 28 that transmits ultrasonic waves is formed to match the inclined surface of the opposing receiving portion 21a.

[0044] The reinforcing piece 27 is provided at a second tip 28 with a holding portion 29 capable of holding the reinforcing member 6. The holding portion 29 is configured to hold the reinforcing member 6, for example, by a vacuum or the like, and a holding method is appropriately selected depending on the material of the member to be held. While holding the reinforcing member 6 with the holding portion 29, the reinforcing piece 27 is moved in an approaching direction 27Y1 (downward direction) in which the second tip 28 approaches the rear surface 10b of the molded ceiling 10 placed on the base 20, thereby placing the reinforcing member 6 in the opening peripheral area 16 (see FIG. 6).

[0045] As shown in FIG. 3, a plate-shaped support member 30 is disposed at a position facing the folding piece 23 in the horizontal direction (front-rear direction) so that its plate surface faces the placement surface 21 of the base 20, in other words, so that its plate surface faces the up-down direction. The support member 30 is configured to be movable back and forth in the horizontal direction by, for example, a cylinder, and can move toward and away from the first tip 24 of the folding piece 23 while facing the first tip 24 of the folding piece 23. The support member 30 is configured to move in the entry direction 30X1 until its tip 30a comes into contact with a position that is the folding base point of the edge portion 15 (see FIG. 4). As a result, the support member 30 can support the edge portion 15 to be folded by the folding piece 23 that has moved in the entry direction 23X1 of the first movement trajectory. The support member 30 is also formed to approximate the shape of the opening 12. This allows the edge portion 15 to be folded so that it can be reliably brought into surface contact with the back surface 10b of the molded ceiling 10, even in cases where wrinkles are likely to occur when folding the edge portion 15, such as in areas where the opening 12 is curved or in corner portions.

[0046] <Manufacturing process for vehicle headliners> Next, a manufacturing method of the molded ceiling 10 according to this embodiment will be described. In this embodiment, the molded ceiling 10 is molded by applying pressure with a mold die whose molding surface is formed into the required curved surface, and then the edge portion 15 along the periphery of the opening 12 provided in the molded ceiling 10 is folded toward the back surface 10b of the molded ceiling 10 and bonded to the back surface 10b of the molded ceiling 10. The manufacturing process of the molded ceiling 10 includes a molding process, an opening forming process, and an end processing process of the opening 12. The end processing process includes a placing process, a folding process, a pressing process, a first welding process, an arrangement process, and a second welding process (fixing process), and the folding process includes a first folding process and a second folding process.

[0047] 1 and 2, in the molding process, a laminate in which a backing material 3 is laminated on the vehicle body side of the base material layer 2 and a skin material 4 is laminated on the vehicle interior side of the base material layer 2 is heated and pressurized in a molding die to integrally mold it into a three-dimensional planar shape. Then, in the opening formation process, an opening 12 corresponding to the sunroof opening in the ceiling panel is provided in the center of the molded ceiling 10.

[0048] Each step included in the terminal processing step will be described below. As shown in Fig. 3, in the placing step, the molded ceiling 10 is placed on the base 20. The molded ceiling 10 is placed so that the front surface 10a faces the placing surface 21 of the base 20 and the edge portion 15 extends outside the base 20 beyond the receiving portion 21a.

[0049] The folding process is a process of folding the edge portion 15 of the opening 12 in the molded ceiling 10 placed on the base 20 from the front surface 10a side to the back surface 10b side of the molded ceiling 10. The edge portion 15 is folded integrally with the laminated skin material 4, base material layer 2, and backing material 3. In the first folding process, as shown in Figs. 4 and 5, the folding piece 23 is moved in the approach direction 23X1 of the first movement trajectory, and the first tip portion 24 of the folding piece 23 is brought into contact with the edge portion 15 of the molded ceiling 10. The folding piece 23 is further moved in the approach direction 23X1 until the first tip portion 24 is at a position where it does not separate from the edge portion 15. As a result, the edge portion 15 is folded in a dogleg shape toward the back surface 10b side of the molded ceiling 10.

[0050] In the first bending step, the folding piece 23 may be inserted while the plate-shaped support member 30 is inserted so as to be close to the back surface 10b of the edge portion 15 of the opening 12 in the molded ceiling 10 placed on the base 20. The tip 30a of the inserted support member 30 is positioned relative to the molded ceiling 10 so as to be in contact with the bending base point of the edge portion 15. As a result, the edge portion 15 is folded onto the plate surface of the support member 30 with the tip 30a of the support member 30 as the base point. Here, the folded edge portion 15 is defined as the folded portion 18. The entering direction 30X1 of the support member 30 is set in the opposite direction to the entering direction 23X1 of the folding piece 23. After the edge portion 15 is folded, the support member 30 moves in the retreating direction 30X2. Then, the second bending step is performed after the support member 30 is retreated.

[0051] In the second bending process, as shown in FIG. 6, the edge portion 15 (bent portion 18) bent in the first bending process is further bent so as to follow the back surface 10b of the molded ceiling 10. Specifically, the bending piece 23 is moved in the entry direction 23Y1 (downward direction) of the second movement trajectory from the position where it was moved in the entry direction 23X1 in the first bending process. This causes the first tip portion 24 to wrap around the bent portion 18 and approach the receiving portion 21a of the base 20. The bent portion 18 is bent so as to be even closer to the back surface 10b of the molded ceiling 10.

[0052] After the second folding step, a pressing step is performed. In the pressing step, the folded portion 18 (folded edge portion 15) and the back surface 10b of the molded ceiling 10 are brought into close contact with each other. In this embodiment, a retracting step is performed in which the folding piece 23 is moved so that the first tip portion 24 is retracted in the thickness direction of the folded folded portion 18 until the folded portion 18 and the back surface 10b of the molded ceiling 10 come into surface contact with each other. Specifically, as shown in FIG. 7, the folding piece 23 is moved from the position where it was lowered in the second folding step in the opposite direction (retracting direction 23X2) to the approach direction 23X1 of the first movement trajectory so that the folding portion 18 is sandwiched between the first tip portion 24 and the receiving portion 21a of the base 20. As a result, the transmission surface 24a of the first tip portion 24 acts as a pressing surface, and the folding portion 18 is pressed toward the receiving portion 21a of the base 20 so as to be compressed in the thickness direction. Then, the folded portion 18 is folded even more firmly and comes into close contact with the back surface 10b of the molded ceiling 10. In this way, by eliminating the gap between the edge portion 15 folded further in the second folding process and the back surface 10b of the molded ceiling 10, the ultrasonic vibrations are reliably transmitted to the area (site) of the molded ceiling 10 where the rolled portion 14 is formed, and the edge portion 15 can be welded and fixed.

[0053] In the first welding step, as shown in Fig. 8, the edge portion 15 (folded portion 18) pressed by the first tip portion 24 and the back surface 10b of the molded ceiling 10 are ultrasonically welded via the first tip portion 24. This forms the end-processed rolled portion 14. When the same number of transmitters as the folding pieces 23 are arranged, each transmitter can simultaneously emit ultrasonic waves to each folding piece 23, and the rolled portion 14 can be formed simultaneously in multiple divided areas. Also, when, for example, there are fewer transmitters than the folding pieces 23 arranged and one transmitter emits ultrasonic waves to multiple folding pieces 23, ultrasonic welding is performed sequentially.

[0054] In the arranging step, the reinforcing member 6 is arranged in the opening peripheral region 16 of the molded ceiling 10. Specifically, as shown in Figs. 5 and 6, the reinforcing member 6 is held by the holding portion 29 of the reinforcing piece 27, and the reinforcing member 6 is moved in the approaching direction 27Y1 (downward direction) to arrange the reinforcing member 6 in a position adjacent to the region where the roll-up portion 14 is to be formed. The holding portion 29 can hold the reinforcing member 6 by, for example, suction or the like. In this embodiment, the reinforcing member 27 descends at the same time as the folding piece 23 descends. That is, the arranging step of the reinforcing member 6 is performed during the second folding step. Note that the arranging step may be performed by manually arranging the reinforcing member 6 in advance and temporarily fixing it, without using the reinforcing piece 27.

[0055] A second welding process (fixing process) is carried out between the second bending process and the end of the first welding process. In the second welding process, the reinforcing member 6 is fixed to the rear surface 10b of the molded ceiling 10 by ultrasonic welding. As shown in Figs. 6 and 7, the reinforcing piece 27, which descends while holding the reinforcing member 6 in the placement process and on which the reinforcing member 6 is placed, functions as a second ultrasonic horn and transmits ultrasonic vibrations to the reinforcing member 6 via the second tip 28. In this embodiment, the second welding process is carried out simultaneously with the retracting process in the pressing process.

[0056] The fixing step of the reinforcing member 6 may be performed by adhering the reinforcing member 6 with an adhesive or double-sided tape instead of ultrasonic welding. For example, the reinforcing member 6 arranged in the opening peripheral region 16 is adhered (fixed) to the back surface 10b of the molded ceiling 10 by applying an adhesive or attaching a double-sided tape in advance to the surface of the reinforcing member 6 to be fixed. The fixing step may be performed simultaneously with the first welding step.

[0057] Next, the flow of the end processing of the opening 12 in the molded ceiling 10 will be described. As shown in FIG. 3, the molded ceiling 10 in which the opening 12 is formed after pressure molding is set on the base 20. The support member 30 moves from a predetermined position (standby position) in an approaching direction 30X1, and approaches the edge 15 of the opening 12 from the back surface 10b side so that the tip 30a of the support member 30 contacts the bending base point of the edge 15. As shown in FIG. 4, the folding piece 23 moves from a predetermined position (standby position) in the approaching direction 23X1 of the first moving trajectory. The first tip 24 of the folding piece 23 contacts the edge 15 from the front surface 10a side of the molded ceiling 10. As the folding piece 23 further moves in the approaching direction 23X1, the edge 15 is bent in a dogleg shape with the tip 30a of the support member 30 as the base point (first folding process). As shown in FIG. 5, after the first bending step, the support member 30 retreats and returns to a predetermined position.

[0058] 6, the folding piece 23 and the reinforcing piece 27 holding the reinforcing member 6 are simultaneously lowered. As the folding piece 23 is lowered, the edge portion 15 (folded portion 18) is further folded by the first tip portion 24 and approaches the rear surface 10b of the molded ceiling 10 (second folding step). As the reinforcing piece 27 is lowered, the reinforcing member 6 is positioned in the opening peripheral region 16, for example, at a position adjacent to the roll-up portion 14 (positioning step).

[0059] 7, the folding piece 23 moves in the retraction direction 23X2 of the first movement trajectory so as to retract the first tip 24 (retraction process). The edge portion 15 (folded portion 18) adjacent to the rear surface 10b of the molded ceiling 10 is pressed and comes into close contact with the rear surface 10b of the molded ceiling 10 (pressing process). While the folding piece 23 moves in the retraction direction 23X2, the reinforcing member 6 is ultrasonically welded via the second tip portion 28 of the reinforcing piece 27 (second welding process).

[0060] As shown in Fig. 8, the reinforcing piece 27 moves in the retreat direction 27Y2 (upward direction), and the edge portion 15 is ultrasonically welded to the rear surface 10b of the molded ceiling 10 via the first tip portion 24 of the bending piece 23 (first welding process). This forms the end-processed rolled portion 14. Thereafter, as shown in Fig. 9, the bending piece 23 moves upward in the retreat direction 23Y2 of the second movement trajectory, and further moves in the retreat direction 23X2 of the first movement trajectory, returning to the predetermined position (standby position). The end-processed product is removed.

[0061] As a modified example of the manufacturing process of the molded ceiling for a vehicle, as shown in Fig. 10, the molded ceiling 10 may be provided with a recess 19 recessed in the thickness direction from the back surface 10b side of the molded ceiling 10 at the folding base point of the edge portion 15. By providing the recess 19 at the folding base point, the folding base point of the edge portion 15 is positioned without using a support member 30 in the first folding step. Therefore, the edge portion 15 can be folded neatly at the folding base point from the first folding step to the second folding step. Note that instead of the recess 19 at the folding base point, a cut portion cut in the thickness direction of the molded ceiling 10 may be provided.

[0062] <Effects of the embodiment> According to the manufacturing process of the molded ceiling 10 according to the above embodiment, the peripheral edge portion 15 of the opening 12 provided in the molded ceiling 10 is bent toward the back surface 10b of the molded ceiling 10 by the bending piece 23 functioning as a first ultrasonic horn. The bent edge portion 15 is pressed by the first tip portion 24 of the bending piece 23. As a result, ultrasonic vibration is transmitted through the first tip portion 24 while the edge portion 15 and the back surface 10b of the molded ceiling 10 are in closer contact with each other, and the edge portion 15 can be reliably ultrasonically welded to the back surface 10b of the molded ceiling 10. Therefore, a series of steps for bending the end of the opening 12 of the molded ceiling 10 and welding it to the back surface 10b of the molded ceiling 10 can be performed automatically, and the quality of the end processing can be stabilized. In addition, since the folding pieces 23 also serve as a jig for folding and ultrasonic welding, there is no need to provide a heating piece or hot air duct for heating the edge portion 15 of the molded ceiling 10 separately from the folding pieces 23, which reduces the burden of heat management on the worker and reduces utility costs for residual heat. Furthermore, when the worker sets or removes the product, the number of high-temperature areas around the worker can be reduced, improving work safety.

[0063] The manufacturing process of the molded ceiling 10 according to the above embodiment includes a first folding process and a second folding process. The edge portion 15 of the opening 12 in the molded ceiling 10 is folded partway along the entering direction 23X1 by the folding piece 23 moving in the entering direction 23X1 of the first moving trajectory, and the first tip portion 24 moving to a position where it does not separate from the edge portion 15 while abutting against the edge portion 15. Then, the folding piece 23 moves from that state in the entering direction 23Y1 (downward direction) of the second moving trajectory, so that the edge portion 15 is further folded along the back surface 10b of the molded ceiling 10. Therefore, it is possible to suppress the occurrence of variations in the base point for folding the edge portion 15 depending on the product.

[0064] In the manufacturing process of the molded ceiling 10 according to the above embodiment, in the pressing step, the folding piece 23 is moved so as to pull in the first tip 24 in the thickness direction of the edge portion 15 (folded portion 18) folded in the second folding step. This presses the folded portion 18 close to the back surface 10b of the molded ceiling 10, folding it even more firmly. Therefore, even if a gap occurs between the folded portion 18 and the back surface 10b of the molded ceiling 10, the folded portion 18 and the back surface 10b of the molded ceiling 10 can be brought into close contact with each other, and ultrasonic vibration can be transmitted to the required area.

[0065] In the manufacturing process of the molded ceiling 10 according to the above embodiment, in the first bending step, the plate-shaped support member 30 sandwiches the edge portion 15 of the molded ceiling 10 and enters a position facing the first tip portion 24 of the bending piece 23 and waits. The tip portion 30a of the support member 30 contacts the bending base point on the back side of the edge portion 15. As a result, the bending piece 23 moves in the entry direction 23X1 of the first movement trajectory, and the edge portion 15 of the molded ceiling 10 is bent onto the plate surface of the plate-shaped support member 30. Therefore, even if the edge portion 15 is difficult to bend due to the material composition of the molded ceiling 10 or the shape of the opening 12, the edge portion 15 can be bent in a stable position with the tip portion 30a of the support member 30 as the base point.

[0066] In the manufacturing process of the molded ceiling 10 according to the above embodiment, in the second welding process (fixing process), the reinforcing member 6 is ultrasonically welded to at least a portion of the opening peripheral region 16 of the molded ceiling 10 by the reinforcing piece 27 functioning as a second ultrasonic horn. By arranging and fixing the reinforcing member 6 in the opening peripheral region 16 of the molded ceiling 10, the strength of the opening peripheral region 16 can be improved. In addition, by performing the second welding process between the second folding process and the end of the first welding process, the reinforcing member 6 can be welded (fixed) at the same time as the terminal processing at the periphery of the opening 12 of the molded ceiling 10. Therefore, the subsequent process can be shortened.

[0067] In the manufacturing process for the molded ceiling 10 according to the above embodiment, in the placement step, the reinforcing member 6 is held by the holding portion 29 of the reinforcing piece 27, moved toward the back surface 10b of the molded ceiling 10, and placed in the opening peripheral area 16. Then, ultrasonic vibrations are transmitted via the second tip portion 28 of the reinforcing piece 27 to ultrasonically weld the placed reinforcing member 6 to the back surface 10b of the molded ceiling 10. Therefore, the reinforcing member 6 can be placed in the opening peripheral area 16 automatically rather than manually, and the process up to ultrasonic welding to the back surface 10b of the molded ceiling 10 can be efficiently performed.

[0068] In the manufacturing process of the molded ceiling 10 according to the above embodiment, the reinforcing member 6 that reinforces the periphery of the opening 12 of the molded ceiling 10 is made of scrap material removed to form the opening 12. In other words, the material of the molded ceiling 10 can be effectively utilized, and the yield can be improved.

[0069] According to the manufacturing process of the molded ceiling 10 according to the above embodiment, the rolled-up portion 14 is formed with terminal processing by ultrasonic welding. In addition, the reinforcing member 6 is placed on the back surface 10b of the molded ceiling 10 and fixed by ultrasonic welding. By performing terminal processing and fixing the reinforcing member 6 by ultrasonic welding in this manner, it is possible to reduce the influence on the molded surface of the molded ceiling 10, such as deformation or scorching due to heating.

[0070] In the manufacturing process of the molded ceiling 10 according to the above embodiment, the bending piece 23 that bends the edge portion 15 of the opening 12 also functions as an ultrasonic horn. This eliminates the need for heating pieces or hot air ducts, so that, for example, it is sufficient to provide the bending piece 23 and support member 30 corresponding to each vehicle model, or only the bending piece 23, and it is possible to reduce the number of jigs for terminal processing required for each vehicle model, thereby reducing equipment costs, etc.

[0071] In the manufacturing process of the molded ceiling 10 according to the above embodiment, the transmission surface 24a of the first tip 24 of the folding piece 23 also acts as a pressing surface that presses the edge portion 15 in the pressing process. This makes it possible to improve the efficiency of a series of processes from bending the edge portion 15 to ultrasonic welding.

[0072] In the manufacturing process of the molded ceiling 10 according to the above embodiment, a retracting process is performed in which the folding piece 23 moves to retract the first tip 24 in the pressing process, so that the edge portion 15 is folded more firmly from the folding base point. Therefore, the edge portion 15 is folded in three stages by the first tip 24 by changing the direction in which the folding piece 23 moves in the order of the approach direction 23X1 of the first movement locus, the approach direction 23Y1 of the second movement locus (downward direction), and the opposite direction to the approach direction 23X1 of the first movement locus (retracting direction 23X2). In addition, from the second folding process to the pressing process, the first tip 24 can fold and press the edge portion 15 from two different directions against the inclined receiving portion 21a. Therefore, the edge portion 15 of the molded ceiling 10 having a thickness including the base layer 2 can be folded firmly until it comes into surface contact with the back surface 10b.

[0073] In the manufacturing process of the molded ceiling 10 according to the above embodiment, the process of arranging the reinforcing member 6 is carried out simultaneously with the second bending process, and the second welding process of welding the reinforcing member 6 is carried out simultaneously with the pulling process (pressing process). In other words, the process of arranging and welding the reinforcing member 6 can be carried out simultaneously with the process of terminal processing of the opening 12. Therefore, it is possible to shorten the post-processing after terminal processing.

[0074] In the manufacturing process of the molded ceiling 10 according to the above embodiment, the reinforcing piece 27 has a holding portion 29 for holding the reinforcing member 6 and also functions as an ultrasonic horn. This reduces the number of necessary tools and cuts down on equipment costs.

[0075] In the manufacturing process of the molded ceiling 10, if a recess 19 recessed in the thickness direction from the back side or a notch cut in the thickness direction is provided at the folding base point of the molded ceiling 10, the base material etc. becomes easy to bend at the folding base point and the folding base point is positioned regardless of the material etc. of the molded ceiling 10. Therefore, even without using the support member 30, the edge portion 15 can be folded at a stable position in the first folding step. Also, when the edge portion 15 is further folded in the second folding step, a neater folding can be achieved.

[0076] In the manufacturing process of the molded ceiling 10, the fixing step may be performed simultaneously with the first welding step. By simultaneously performing the fixing of the reinforcing member 6 to the back surface 10b of the molded ceiling 10 and the ultrasonic welding of the edge portion 15, the post-process of the end treatment can be shortened, and the efficiency of the entire process can be improved.

[0077] The reinforcing member 6 may be selected from plastic, resin, metal plate, wood, etc. In other words, it is possible to manufacture a molded ceiling 10 in which the opening peripheral region 16 is reinforced by the reinforcing member 6 made of various materials.

[0078] The manufacturing method for a molded ceiling for a vehicle according to the present invention is not limited to the appearance, configuration, etc. described in the above embodiment, but can be embodied in various other forms by various modifications, additions, deletions, and combinations of configurations without changing the gist of the present invention.

[0079] The first and second movement paths along which the bending piece 23 according to the embodiment moves are set arbitrarily. For example, they may be paths along which the bending piece 23 moves in three dimensions. In addition, the advancement direction and retreat direction of the bending piece 23, the reinforcing piece 27, and the support member 30 are also set arbitrarily and appropriately.

[0080] In the above embodiment, an example was shown in which the reinforcing piece 27 lowers while holding the reinforcing member 6 with the holding portion 29 during the placement process, thereby placing the reinforcing member 6 on the back surface 10b of the molded ceiling 10, but this is not limited to this, and a method in which the reinforcing member 6 is manually placed and temporarily fixed may also be adopted.

[0081] The positions and number of the reinforcing members 6 arranged in the opening peripheral region 16 of the molded ceiling 10 are appropriately selected according to need. Also, the molded ceiling 10 may be configured without the reinforcing members 6.

[0082] The timing of the second welding step of welding the reinforcing member 6 is not limited to the same time as the retracting step, but may be appropriately set. For example, the reinforcing member 6 may be welded simultaneously with the first welding step. Also, the reinforcing member 6 may be welded during the bending step of the edge portion 15.

[0083] The method of fastening the reinforcing member 6 is not limited to ultrasonic welding, and various methods can be selected depending on the material of the reinforcing member 6. For example, the reinforcing member 6 may be adhered (fastened) with an adhesive or double-sided tape.

[0084] In the above embodiment, an example is shown in which the edge portion 15 is supported by the support member 30 during the folding process, but a method of folding the edge portion 15 without using the support member 30 may be adopted depending on the material of the molded ceiling 10, for example, when the base material layer 2 is easily bent.

[0085] Although an example of a configuration in which a urethane foam core material and a fiber reinforcement material are laminated has been shown as the configuration of the base material layer 2 according to the above embodiment, various configurations can be applied without being limited to this. For example, a molded body in which fiber layers made of nonwoven fabric are laminated on both sides of a core material containing glass fiber and thermoplastic resin, or a molded nonwoven fabric may be selected as the configuration of the base material layer. [Explanation of symbols]

[0086] 2 Base material layer 3 Backing 4 Skin material 6 Reinforcement members 10 Molded ceiling (molded ceiling for vehicles) 10a Molded ceiling surface 10b Back side of molded ceiling 12 Opening 14 Winding section 15 Edge 16 Area around the opening (area around the opening) 18 Bend part (edge ​​part) 19 Recess 20 Foundations 21 Placement surface 21a Receiving part 23 Folding piece 23X1 Entry direction of the first movement trajectory 23Y1 Direction of entry of second movement trajectory 24 1st tip 27 Reinforcement piece 28 Second tip 29 Holding part 30 Support member 30a Tip of support member

Claims

1. A method for manufacturing a molded ceiling for a vehicle, comprising the steps of: forming a molded ceiling by applying pressure with a mold having a molding surface formed to a required curved surface; bending an edge portion along a periphery of an opening provided in the molded ceiling toward a back surface side of the molded ceiling; and bonding the edge portion to the back surface of the molded ceiling, The molded ceiling is configured to have a planar backing material containing a thermoplastic resin on the back side, A step of placing the molded ceiling on a support surface of a base having a receiving portion that supports the periphery of the opening, such that the surface side of the molded ceiling faces the support surface of the base and the edge portion extends outside the base from the receiving portion; a bending step of bending the edge portion by a bending piece having a first tip portion capable of transmitting ultrasonic vibration and functioning as a first ultrasonic horn so that the edge portion is aligned with a back surface of the molded ceiling; a pressing process in which the edge portion is pressed toward the receiving portion of the base by the first tip portion so that the edge portion bent in the bending process and the back surface of the molded ceiling are in close contact with each other; a first welding process, in which the edge portion pressed by the first tip portion and the back surface of the molded ceiling are ultrasonically welded together via the first tip portion to form a welded rolled-up portion.

2. A method for manufacturing a vehicle roof according to claim 1, comprising the steps of: The bending step includes: a first bending process, in which the bending piece is moved in a direction of approach of a first moving trajectory in which the first tip portion approaches the edge portion of the molded ceiling placed on the base from the front side of the molded ceiling, so that the first tip portion abuts against the edge portion of the molded ceiling, and further, the bending piece is moved to a position where the first tip portion does not separate from the edge portion, thereby bending the edge portion from the front side to the back side of the molded ceiling; A manufacturing method for a molded ceiling for a vehicle includes a second bending process, in which the bending piece is moved in the entry direction of a second moving trajectory in which the first tip portion approaches the back surface of the molded ceiling placed on the base, thereby further bending the edge portion bent in the first bending process so as to follow the back surface of the molded ceiling.

3. A method for manufacturing a vehicle roof according to claim 2, comprising the steps of: The pressing step includes: a retracting step of moving the folding piece so as to retract the first tip portion in a thickness direction of the edge portion further bent in the second bending step until the edge portion and the rear surface of the molded ceiling come into surface contact with each other; The method for manufacturing a molded ceiling for a vehicle, wherein the edge portion is pressed by the first tip portion retracted in the retracting step.

4. The method for manufacturing a vehicle molded ceiling according to claim 2 or 3, The first folding step includes: a plate-shaped support member disposed to be movable toward and away from the first tip portion and having a plate surface facing the mounting surface of the base; An operation of the support member entering close to the back side of the edge portion of the molded ceiling placed on the base; and positioning the tip of the support member against the molded ceiling so as to be in contact with the folding origin of the edge portion; a step of bending the edge portion onto a plate surface of the support member by moving the bending piece in an approach direction of the first movement trajectory, A manufacturing method for a vehicle molded ceiling, wherein after the edge portion is bent in the first bending step, the support member is retracted, and after the support member is retracted, the second bending step is performed.

5. The method for manufacturing a vehicle molded ceiling according to claim 2 or 3, The molded ceiling has a recess recessed in the thickness direction from the back side of the molded ceiling or a cut portion cut in the thickness direction at the folding base point of the edge portion, In the first folding step and the second folding step, the edge portion is folded at the folding base point.

6. The method for manufacturing a vehicle molded ceiling according to claim 2 or 3, A placement process for placing a reinforcing member that reinforces the periphery of the opening in at least a portion of the peripheral area of ​​the opening on the rear surface of the molded ceiling; and a fixing step of fixing the reinforcing member to the rear surface of the molded ceiling. The method for manufacturing a molded ceiling for a vehicle, wherein the fixing step is performed between the second folding step and the end of the first welding step.

7. A method for manufacturing a vehicle roof according to claim 6, comprising the steps of: The manufacturing method for a molded ceiling for a vehicle, wherein the fixing process includes a second welding process in which the reinforcing member is ultrasonically welded to the back surface of the molded ceiling by a reinforcing piece having a second tip portion capable of transmitting ultrasonic vibrations and functioning as a second ultrasonic horn.

8. A method for manufacturing a vehicle molded ceiling according to claim 7, comprising the steps of: the reinforcing piece has a holding portion at the second tip portion capable of holding the reinforcing member, The positioning process of this method for manufacturing a molded ceiling for a vehicle includes moving the reinforcing piece in a direction such that the second tip portion approaches the back surface of the molded ceiling placed on the base while holding the reinforcing member with the holding portion, thereby positioning the reinforcing member in the peripheral area of ​​the opening.

9. A method for manufacturing a vehicle roof according to claim 6, comprising the steps of: The method for manufacturing a molded ceiling for a vehicle, wherein the fixing step is performed simultaneously with the first welding step.

10. A method for manufacturing a vehicle roof according to claim 6, comprising the steps of: A method for manufacturing a molded ceiling for a vehicle, wherein the reinforcing member is made from scrap material from a portion of the molded ceiling that has been removed to form the opening.

11. A method for manufacturing a vehicle roof according to claim 6, comprising the steps of: The method for manufacturing a molded vehicle ceiling, wherein the reinforcing member is selected from plastic, resin, metal plate, or wood.

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